Engine Replacement

Engine Replacement

Removal Procedure

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable.
3. Remove the air outlet duct . Refer to Air Cleaner Outlet Resonator Replacement Service and Repair.






4. Secure the cooling module to the upper body structure.
5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.






6. Disconnect the fuel line from the fuel rail.
7. Remove the supercharger. Refer to Supercharger Replacement Service and Repair.
8. Remove the charge air radiator hose. Refer to Charge Air Cooler Inlet Hose Replacement Service and Repair.
9. Remove the charge air cooler hose. Refer to Charge Air Cooler Outlet Hose Replacement .Service and Repair
10. Drain the cooling system. Refer to Cooling System Draining and Filling Service and Repair.
11. Remove the radiator inlet hose.
12. Remove the surge tank to cylinder head pipe. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement and Radiator Surge Tank Outlet Hose/Pipe Replacement Service and Repair.
13. Remove the radiator outlet hose.






14. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement Service and Repair.






15. Disconnect the following harness connectors:
- TMAP sensor
- ETC
- Map sensor
- BARO sensor
- Crankshaft sensor
- Oil pressure sensor
- Purge solenoid
- Ignition coil modules
- O2 sensor
- Vehicle speed sensor
- Engine temperature sensor
- Boost solenoid
- Back-up lamp switch
16. Remove the engine drive belt. Refer to Drive Belt Replacement Service and Repair.
17. Disconnect the charge air cooler hoses.
18. Raise and suitably support the vehicle.
19. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Service and Repair.






20. Disconnect the compressor and condenser hose assembly from the compressor.
21. Remove the AC compressor bolts and set the compressor aside.






22. Disconnect the starter harness connectors (3,4,5).
23. Disconnect the generator harness connectors.
24. Drain the engine oil.
25. Disconnect the front exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Replacement Service and Repair.
26. Disconnect the transmission shift cable from the transmission.
27. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
28. Remove the engine mount. Refer to Engine Mount Replacement [1][2]Engine Mount Replacement.






29. Remove the left transmission mount. Refer to Transmission Mount Replacement Service and Repair.






30. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement Service and Repair.






31. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement Service and Repair.






Important: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

32. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement Service and Repair.






33. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement Service and Repair.






34. Disconnect the drive axles from the steering knuckle. Refer to Wheel Drive Shaft Replacement Service and Repair.
35. Use a paint pen or magic marker in order to mark the frame to body position.






36. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
37. Use wood blocks as necessary between the lift table and the frame to support the assembly.
38. Slowly remove the frame bolts using the following sequence:
38.1. Remove the front frame bolts.
38.2. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
39. Slowly lower the table to the floor.
40. Attach the engine lift hoist to the engine lift hooks.






41. Remove the starter.
42. Remove the transmission to engine bolts.
43. Separate the engine from the transmission.
44. Remove the clutch pressure plate and disk.
45. Remove the following components:
- Exhaust manifold
- Exhaust manifold studs
- Engine mount bracket
- Fuel rail
- Thermostat housing and feed pipe
- Generator
46. Remove the engine from the engine lift.

Installation Procedure

1. Attach the engine lift hoist to the engine lift hooks.
2. Install the following components:
- Exhaust manifold
- Refer to Exhaust Manifold Replacement Service and Repair.
- Engine mount bracket
- Refer to Engine Mount Bracket Replacement [1][2]Engine Mount Replacement.
- Fuel rail
- Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair.
- Idler pulley
- Drive belt tensioner
- Refer to Drive Belt Tensioner Replacement - Supercharger Service and Repair.
- Thermostat housing and feed pipe
- Refer to Engine Coolant Thermostat Replacement Service and Repair.
- Generator
- Refer to Generator Replacement Service and Repair.
- Flywheel
- Refer to Engine Flywheel Replacement Service and Repair.
- Clutch pressure plate and disk
- Refer to Clutch Pressure and Driven Plate Replacement Service and Repair.
- AC Compressor
- Refer to Air Conditioning Compressor Replacement Service and Repair.
3. Align the engine to the transmission.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.






Important: The number 3 bolt location is not used.

4. Secure the engine to the transmission.

Tighten
Tighten the transmission to engine bolts to 75 Nm (55 lb ft).






5. Install the starter. Refer to Starter Motor Replacement Service and Repair.
6. Remove the engine lift from the engine.






7. Raise and position the frame and powertrain assembly to the vehicle.
8. Hand start all the frame bolts while aligning the frame to the paint marks.
9. Tighten the frame bolts.

Tighten
Tighten the frame bolts to 100 Nm (74 lb ft) plus 180 degrees.

10. Remove the lift table.






11. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement Service and Repair.






12. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement Service and Repair.






13. Connect the intermediate steering shaft to the steering gear. Refer to Steering Gear Replacement Service and Repair.






14. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement Service and Repair.






15. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement Service and Repair.






16. Install the left transmission mount. Refer to Transmission Mount Replacement - Left Side Service and Repair.






17. Install the engine mount. Refer to Engine Mount Replacement [1][2]Engine Mount Replacement.
18. Remove the wood blocks between the powertrain and frame.
19. Connect the transmission shift cable to the transmission.






20. Connect the exhaust takedown pipe to the exhaust manifold.

Tighten
Tighten the nuts to 30 Nm (22 lb ft).

21. Connect the generator harness connectors.

Tighten
Tighten the generator terminal nut to 20 Nm (15 lb ft).






22. Connect the starter harness connectors (3,4,5).

Tighten
Tighten the battery terminal nut to 17 Nm (13 lb ft).

Tighten
Tighten the S-terminal nut to 3 Nm (27 lb in).

23. Install the compressor and condenser hose assembly to the compressor. Refer to Compressor Hose Assembly Replacement .
24. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging Service and Repair.
25. Install the supercharger. Refer to Supercharger Replacement Service and Repair.
26. Install the engine drive belt. Refer to Drive Belt Replacement Service and Repair.
27. Connect the charge air cooler hoses.
28. Connect the following harness connectors:
- TMAP sensor
- ETC
- Map sensor
- Crankshaft sensor
- Oil pressure sensor
- Purge solenoid
- BARO sensor
- Ignition coil modules
- O2 sensor
- Vehicle speed sensor
- Engine temperature sensor
- Boost solenoid







29. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement Service and Repair.
30. Install the radiator outlet hose. Refer to Radiator Inlet Hose Replacement Service and Repair.






31. Connect the fuel line to the fuel rail.
32. Install the surge tank to the cylinder head pipe.

Tighten
Tighten the bolt to 10 Nm (89 lb in).






33. Release the cooling module from the upper body structure.
34. Install the air outlet duct . Refer to Air Cleaner Outlet Resonator Replacement Service and Repair.
35. Connect the negative battery cable.
36. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations Capacity Specifications.
37. Fill the cooling system. Refer to Cooling System Draining and Filling Service and Repair.
38. Road test the vehicle.